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A-4JA1
Isuzu A-4JA1 User Manual
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16
MEMO
18
20
Table of Contents
Table of Contents
3
General Information
4
General Repair Instructions
5
Notes on the Format of this Manual
5
General Information
7
Main Data and Specifications
9
Standard Bolt
10
Tightening Torque Specifications
10
Tightening Torque Specifications
11
Flanged Head Bolt
11
Special Parts Fixing Nuts and Bolts
12
Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
12
Timing Gear Case, Flywheel Housing, Camshaft, and Timing Gear
14
Cooling and Lubricating System
15
Intake and Exhaust Manifold
16
Engine Electrical
17
Fuel Injection System
18
Maintenance
20
Engine Serial Number
21
Injection Pump Identification
21
Lubricating System
21
Main Oil Filter
21
Model Identification
21
Fuel Filter
22
Fuel System
22
Air Bleeding
23
Water Separator (Water Sedimentor)
23
Injection Nozzle
24
Injection Nozzle Adjustment
24
Injection Nozzle Inspection
24
Spray Condition
24
Cooling Fan Drive Belt
25
Cooling System
25
Operating Test
25
Thermostat
25
Valve Clearance Adjustment
26
In-Line Type Injection Pump
27
Injection Timing
27
Injection Timing Confirmation Procedure
27
Distributor Type Injection Pump
28
Pump Fixing Bolt
28
Compression Pressure Measurement
29
Engine Oil Viscosity Chart
30
Engine Oil Viscosity Grade – Ambient Temperature
30
Recommended Lubricants
30
Engine Repair Kit
31
Section 3. Engine Assembly (1)
32
Engine Assembly (1)
32
Disassembly
34
Fuel Injection Pipe with Clip
35
Injection Pump
35
Exhaust Manifold
35
Injection Nozzle Holder
38
Rocker Arm Shaft and Rocker Arm
38
Cylinder Head
38
Crankshaft Damper Pulley with Dust Seal
39
Idler Gear
39
Timing Gear Backlash Measurement
39
Idler Gear “A” End Play Measurement
39
Piston and Connecting Rod with Upper Bearing
40
Connecting Rod Cap with Lower Bearing
40
Camshaft with Camshaft Timing Gear and Thrust Plate
40
Flywheel
40
Crankshaft Bearing Cap with Lower Bearing
41
Crankshaft Upper Bearing
41
Tappet
41
Crankshaft Rear Oil Seal
41
Single Unit
42
Rocker Arm Shaft Bracket
43
Rocker Arm Shaft Snap Ring
43
Split Collar
45
Intake and Exhaust Valve
45
Piston and Connecting Rod
46
Connecting Rod Bearing
47
Piston Ring
47
Piston Pin Snap Ring
47
Piston Pin
47
Camshaft, Camshaft Timing Gear, and Thrust Plate
48
Camshaft Timing Gear
49
Thrust Plate
49
Engine Assembly (2)
50
Cylinder Head Lower Face Warpage
51
Exhaust Manifold Fitting Face Warpage
51
Cylinder Head Height (Reference)
51
Inspection and Repair
51
Valve Guide
52
Manifold Fitting Face Warpage
52
Valve Stem and Valve Guide Clearance
52
Valve Guide Replacement
52
Valve and Valve Seat Insert
53
Valve Guide Installation
53
Valve Stem Outside Diameter
53
Valve Thickness
53
Valve Seat Insert Removal
54
Valve Seat Insert Replacement
54
Valve Depression
54
Valve Contact Width
54
Valve Seat Insert Installation
55
Valve Seat Insert Correction
55
Valve Spring
56
Valve Spring Free Height
56
Valve Spring Inclination
56
Valve Spring Tension
56
Rocker Arm Shaft and Rocker Arm Clearance
57
Rocker Arm Shaft Run-Out
57
Rocker Arm Shaft Outside Diameter
57
Rocker Arm Correction
58
Cylinder Body
58
Cylinder Body Upper Face Warpage
58
Cylinder Liner Bore Measurement
59
Cylinder Liner Projection Inspection
59
Cylinder Body Bore Measurement
60
Cylinder Liner Removal
60
Cylinder Liner Grade Selection
60
Cylinder Liner Replacement
60
Cylinder Liner Installation
61
Piston Selection
62
Piston Grade Selection
63
Piston Grade
63
Cylinder Liner and Piston Clearance
63
Tappet and Push Rod
64
Tappet Outside Diameter
64
Push Rod Curvature
65
Tappet and Cylinder Body Clearance
65
Camshaft
65
Camshaft Journal Diameter
65
Camshaft and Camshaft Bearing
66
Camshaft Bearing Replacement
66
Camshaft Run-Out
66
Cam Height
66
Camshaft Bearing Installation
67
Camshaft End Play
67
Thrust Plate Replacement
67
Thrust Plate Removal
67
Crankshaft and Bearing
68
Crankshaft Tufftriding Inspection
68
Judgment
68
Crankshaft Journal and Crankpin Diameter
69
Crankshaft Run-Out
69
Bearing Tension
69
Crankshaft Journal and Bearing Clearance
70
Connecting Rod Bearing Inside Diameter
70
Crankpin and Bearing Clearance
71
Crankshaft Timing Gear Replacement
73
Crankshaft Timing Gear Removal
73
Crankshaft Timing Gear Installation
73
Crankshaft Pilot Bearing Installation
74
Crankshaft Pilot Bearing Replacement
74
Crankshaft Pilot Bearing
74
Flywheel and Ring Gear
75
Ring Gear
75
Ring Gear Installation
76
Piston
76
Piston Ring Gap
76
Piston Ring and Piston Ring Groove Clearance
77
Piston Ring and Piston Ring Groove
77
Piston Pin Diameter
78
Piston Pin and Piston Clearance
78
Connecting Rod Bushing Removal
78
Connecting Rod Bushing Installation
79
Connecting Rod Alignment
79
Idler Gear Shaft and Idler Gear
80
Connecting Rod Side Face Clearance
80
Idler Gear Shaft Outside Diameter
80
Crankshaft Front Oil Seal Replacement
81
Idler Gear “A” Inside Diameter
81
Timing Gear Case Cover
81
Oil Seal Installation
82
Engine Assembly (3)
84
Reassembly
85
Rocker Arm Shaft
86
Valve Stem Oil Seal
88
Crankcase
100
Oil Pump with Oil Pipe
101
Flywheel Housing
101
Flywheel Housing Bolt Torque
101
Oil Pan
102
Intake Manifold
108
Lubricating System
112
Item
113
Main Data and Specifications
113
General Description
114
Lubricating Oil Flow
114
Oil Pump
117
Vane and Pump Body Clearance
118
Oil Filter with Built-In Oil Cooler
120
Rotor and Vane Clearance
118
Vane, Rotor, and Cover Clearance
118
Relief Valve
121
Oil Cooler
121
Relief Vale
123
Cooling System
124
Item
125
Main Data and Specifications
125
Coolant Flow
126
General Description
126
Water Pump
127
Water Pump
128
Bearing Unit
130
Cooling Fan Center
132
Impeller and Seal Unit
132
Set Screw
132
Thermostat
134
Fuel System
136
Item
137
Main Data and Specifications
137
General Description
138
Fuel Filter and Water Separator
140
Injection Nozzle
141
Injection Nozzle Needle Inspection
143
Nozzle Body and Needle Valve Inspection
143
Nozzle Lapping Procedure
143
Injection Pump Data
146
Injection Volume Adjustment
146
Governor Adjustment
147
Injection Quantity
147
Full Adjustment
147
Speed Lever Angle
148
Section 9. Engine Electricals
150
Engine Electricals
150
Starter Identification
151
Armature
157
Armature Short Circuit Test
157
Armature Winding Ground Test
157
Armature Winding Continuity Test
157
Commutator Run-Out Test
158
Commutator Outside Diameter Measurement
158
Commutator Outside Diameter
158
Segment Mica Depth Measurement
158
Field Winding Continuity Test
159
Brush and Brush Holder
159
Field Winding Ground Test
159
Yoke
159
Brush Spring Inspection
160
Brush Holder Insulation Test
160
Pinion Clutch
160
Pinion Inspection
160
Pinion
163
Dust Cover
163
Shift Lever
163
Torsion Spring
163
Through Bolt
164
Lead Wire
164
Inspection after Reassembly
164
When Pinion Gap Deviates from Specified Value
164
Alternator
165
Alternator Identification
165
Rectifier with Brush Holder
169
Rotor and Bearing
169
Front Cover
169
Pulley and Fan
169
Ball Bearing
170
Rotor Coil Continuity Test
171
Rotor Coil Ground Test
171
Stator Coil Continuity Test
171
Stator Coil Ground Test
172
Rectifier (Positive Diode) Continuity Test
172
Rectifier (Negative Diode) Continuity Test
173
Rectifier Assembly Replacement Procedure
173
Brush
174
Section 10. Troubleshooting
178
Hard Starting
180
Starter Inoperative
180
Starter Operates but Engine Does Not Turn over
181
Engine Turns over but Does Not Start
182
Fuel Is Not Being Delivered to the Injection Pump
182
Fuel Is Being Delivered to the Injection Pump
183
Unstable Idling
184
Unstable Idling
186
Insufficient Power
187
Excessive Fuel Consumption
191
Excessive Oil Consumption
193
Overheating
194
White Exhaust Smoke
196
Dark Exhaust Smoke
197
Oil Pressure Does Not Rise
198
Abnormal Engine Noise
200
Engine Knocking
200
Continuous Noise
201
Gas Leakage Noise
201
Slapping Noise
202
Section 11. Special Tool List
204
Special Tool List
205
General Rules
208
Section 12. Repair Standards
208
Millimeters to Inches
222
Inches to Millimeters
222
Section 13. Conversion Table
222
Feet to Meters
223
Length
223
Meters to Feet
223
Miles to Kilometers
223
Area
224
Cubic Centimeters to Cubic Inches
224
Cubic Inches to Cubic Centimeters
224
Square Centimeters to Square Inches
224
Square Inches to Square Centimeters
224
Volume
224
Gallons (Imp.) to Liters
225
Gallons (U.s.) to Liters
225
Liters to Gallons (Imp.)
225
Liters to Gallons (U.s.)
225
Kilograms to Newton
226
Kilograms to Pounds
226
Mass
226
Newton to Kilograms
226
Pounds to Kilograms
226
Kilo Pascal to Kilograms Per Square Centimeters
227
Kilograms Per Square Centimeters to Kilo Pascal
227
Kilograms Per Square Centimeters to Pounds Per Square Inches
227
Pounds Per Square Inches to Kilograms Per Square Centimeters
227
Pressure
227
Foot Pounds to Kilogrammeters
228
Kilogrammeters to Foot Pounds
228
Kilogrammeters to Newtonmeters
228
Torque
228
Temperature
229
Fahrenheit to Centigrade
229
Centigrade to Fahrenheit
229
4
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Isuzu A-4JA1 Specifications
General
Cylinder Arrangement
Inline-4
Fuel System
Direct Injection
Aspiration
Turbocharged
Cooling System
Water-cooled
Displacement
2.5L
Engine Type
Diesel
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